U.S. patent application number 16/990578 was filed with the patent office on 2021-02-18 for fast pattern recognition using ultrasound.
The applicant listed for this patent is GE Sensing & Inspection Technologies, GmbH. Invention is credited to Prashanth Kumar Chinta, Thomas Wuerschig.
Application Number | 20210048413 16/990578 |
Document ID | / |
Family ID | 1000005019457 |
Filed Date | 2021-02-18 |
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United States Patent
Application |
20210048413 |
Kind Code |
A1 |
Chinta; Prashanth Kumar ; et
al. |
February 18, 2021 |
FAST PATTERN RECOGNITION USING ULTRASOUND
Abstract
Systems and methods for ultrasonic testing are provided. An
ultrasonic probe including a phased transducer array can transmit a
plurality of ultrasonic beams (e.g., plane waves) oriented at
different directions simultaneously into a target. The plurality of
ultrasonic transducers transmitting the ultrasonic waves can also
receive ultrasonic echoes resulting from reflection of the
plurality of plane waves from the target. Each ultrasonic
transducer can measure a single A-scan characterizing the
ultrasonic echoes received at that ultrasonic transducer. Based
upon A-scans received from the plurality of transducers, a
controller can generate an image representing the target and output
the image for display by a display device substantially
concurrently with transmission of the ultrasonic waves, allowing
for real-time display.
Inventors: |
Chinta; Prashanth Kumar;
(Hurth, DE) ; Wuerschig; Thomas; (Cologne,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GE Sensing & Inspection Technologies, GmbH |
Hurth |
|
DE |
|
|
Family ID: |
1000005019457 |
Appl. No.: |
16/990578 |
Filed: |
August 11, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62885813 |
Aug 12, 2019 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01N 29/07 20130101;
G01N 29/4454 20130101; G01N 29/069 20130101; G01N 29/262
20130101 |
International
Class: |
G01N 29/06 20060101
G01N029/06; G01N 29/07 20060101 G01N029/07; G01N 29/26 20060101
G01N029/26; G01N 29/44 20060101 G01N029/44 |
Claims
1. A method, comprising: positioning an ultrasonic probe adjacent
to a target, the ultrasonic probe including a plurality of
ultrasonic transducers arranged in a predetermined array;
transmitting, by the plurality of ultrasonic transducers,
respective ultrasonic waves to form a plurality of plane waves,
wherein the plurality of plane waves are oriented at different
predetermined directions with respect to a reference axis and the
plurality of plane waves are transmitted substantially
simultaneously into the target; receiving, by the plurality
ultrasonic transducers, ultrasonic echoes resulting from reflection
of the plurality of plane waves from the target; measuring, by each
ultrasonic transducer of the plurality of ultrasonic transducers, a
single A-scan characterizing the ultrasonic echoes received at that
ultrasonic transducer; generating, by a controller based upon the
measured A-scans, an image representing the target; and outputting,
by the controller, data representing the generated image to a
display device.
2. The method of claim 1, wherein the plurality of ultrasonic
transducers are a phased array.
3. The method of claim 1, wherein the plurality of plane waves are
not transmitted sequentially.
4. The method of claim 1, wherein an amount of data contained
within the single A-scan is less than an amount of data contained
within a plurality of A-scans acquired by full matrix capture
(FMC).
5. The method of claim 1, wherein an amount of data contained
within the single A-scan is less than an amount of data contained
within a plurality of A-scans acquired by plane wave imaging
(PWI).
6. The method of claim 1, wherein a rate of data generated during
measurement of the single A-scan is less than a rate of data
generated during measurement of a plurality of A-scans acquired by
full matrix capture (FMC).
7. The method of claim 1, wherein a rate of data generated during
measurement of the single A-scan is less than a rate of data
generated during measurement of a plurality of A-scans acquired by
plane wave imaging (PWI).
8. An ultrasonic testing system, comprising: an ultrasonic probe
including a plurality of ultrasonic transducers arranged in a
predetermined array, the plurality of ultrasonic transducers being
configured to: transmit respective ultrasonic waves in response to
receipt of control signals to form a plurality of plane waves,
wherein the plurality of plane waves are oriented at different
predetermined directions with respect to a reference axis and the
plurality of plane waves are transmitted substantially
simultaneously into the target; receive ultrasonic echoes resulting
from reflection of the plurality of plane waves from the target;
and measure a single A-scan characterizing the ultrasonic echoes
received at respective ones of the plurality of ultrasonic
transducers; and a controller including one or more processors and
configured to: transmit the control signals to the plurality of
ultrasonic transducers; generate, based upon the measured A-scans,
an image representing the target; and output data representing the
generated image to a display device.
9. The system of claim 8, wherein the plurality of ultrasonic
transducers are a phased array.
10. The system of claim 8, wherein the plurality of plane waves are
not transmitted sequentially.
11. The system of claim 8, wherein an amount of data contained
within the single A-scan is less than an amount of data contained
within a plurality of A-scans acquired by full matrix capture
(FMC).
12. The system of claim 8, wherein an amount of data contained
within the single A-scan is less than an amount of data contained
within a plurality of A-scans acquired by plane wave imaging
(PWI).
13. The system of claim 8, wherein a rate of data generated during
measurement of the single A-scan is less than a rate of data
generated during measurement of a plurality of A-scans acquired by
full matrix capture (FMC).
14. The system of claim 8, wherein a rate of data generated during
measurement of the single A-scan is less than a rate of data
generated during measurement of a plurality of A-scans acquired by
plane wave imaging (PWI).
15. A non-transitory computer program product which, when executed
by at least one data processor forming part of at least one
computer, result in operations comprising: transmitting, by a
plurality of ultrasonic transducers arranged in a predetermined
array, respective ultrasonic waves to form a plurality of plane
waves, wherein the plurality of plane waves are oriented at
different predetermined directions with respect to a reference axis
and the plurality of plane waves are transmitted substantially
simultaneously into the target; receiving, by the plurality
ultrasonic transducers, ultrasonic echoes resulting from reflection
of the plurality of plane waves from the target; measuring, by each
ultrasonic transducer of the plurality of ultrasonic transducers, a
single A-scan characterizing the ultrasonic echoes received at that
ultrasonic transducer; generating, by a controller based upon the
measured A-scans, an image representing the target; and outputting,
by the controller, data representing the generated image to a
display device.
16. The computer program product of claim 15, wherein the plurality
of plane waves are not transmitted sequentially.
17. The computer program product of claim 15, wherein an amount of
data contained within the single A-scan is less than an amount of
data contained within a plurality of A-scans acquired by full
matrix capture (FMC).
18. The computer program product of claim 15, wherein an amount of
data contained within the single A-scan is less than an amount of
data contained within a plurality of A-scans acquired by plane wave
imaging (PWI).
19. The computer program product of claim 15, wherein a rate of
data generated during measurement of the single A-scan is less than
a rate of data generated during measurement of a plurality of
A-scans acquired by full matrix capture (FMC).
20. The computer program product of claim 15, wherein a rate of
data generated during measurement of the single A-scan is less than
a rate of data generated during measurement of a plurality of
A-scans acquired by plane wave imaging (PWI).
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 62/885,813, filed Aug. 12, 2019, entitled
"Fast Pattern Recognition Using Ultrasound," the entirety of which
is incorporated by reference.
BACKGROUND
[0002] Non-destructive testing (NDT) is a class of analytical
techniques that can be used to inspect characteristics of a target,
without causing damage, to ensure that the inspected
characteristics of the target satisfy required specifications. NDT
can be useful in industries that employ structures that are not
easily removed from their surroundings (e.g., pipes or welds) or
where failures would be catastrophic. For this reason, NDT can be
used in a number of industries such as aerospace, power generation,
oil and gas transport or refining. Ultrasonic testing is one type
of NDT. Ultrasound is acoustic (sound) energy in the form of waves
that have an intensity (strength) which varies in time at a
frequency above the human hearing range. In ultrasonic testing, one
or more ultrasonic waves can be directed towards a target in an
initial pulse. As an ultrasonic wave travels through the target, it
can reflect from features such as outer surfaces and interior
defects (e.g., cracks, porosity, inhomogeneities, etc.), referred
to as an ultrasonic echo. An ultrasonic sensor can acquire
measurements characterizing ultrasonic echoes resulting from that
initial pulse (e.g., amplitude of the echo and time of flight of
measured echoes), and the acquired echo measurements can be
analyzed to determine target and defect characteristics.
[0003] Techniques have been developed to provide multi-dimensional
images of defects within the target in real-time from ultrasonic
testing data. Real time imaging can be desirable to allow
inspectors to see imaged defects while ultrasonic testing is
performed. However, existing imaging techniques can acquire a large
amount of ultrasonic data and, in order to process this volume of
ultrasonic data rapidly enough to produce images in real time,
sophisticated and costly electronics can be required. Thus,
existing ultrasonic testing systems capable of multi-dimensional
defect imaging can be relatively expensive.
SUMMARY
[0004] In general, systems and methods are provided for improved
ultrasonic data acquisition for ultrasonic imaging. As discussed in
detail below, ultrasonic data acquisition systems and methods are
provided which reduce collection of unnecessary and/or redundant
ultrasonic data. By reducing the amount of ultrasonic data that is
acquired for analysis, ultrasonic images can be generated in
real-time by cheaper microprocessors, without the need for
expensive electronics, such as field programmable gate arrays
(FPGAs).
[0005] In an embodiment, a method of ultrasonic testing is
provided. The method can include positioning an ultrasonic probe
adjacent to a target, the ultrasonic probe including a plurality of
ultrasonic transducers arranged in a predetermined array. The
method can also include transmitting, by the plurality of
ultrasonic transducers, respective ultrasonic waves to form a
plurality of plane waves. The plurality of plane waves can be
oriented at different predetermined directions with respect to a
reference axis and the plurality of plane waves are transmitted
substantially simultaneously into the target. The method can
further include receiving, by the plurality ultrasonic transducers,
ultrasonic echoes resulting from reflection of the plurality of
plane waves from the target. The method can additionally include
measuring, by each ultrasonic transducer of the plurality of
ultrasonic transducers, a single A-scan characterizing the
ultrasonic echoes received at that ultrasonic transducer. The
method can further include generating, by a controller based upon
the measured A-scans, an image representing the target. The method
can also include outputting, by the controller, data representing
the generated image to a display device.
[0006] In another embodiment of the method, the plurality of
ultrasonic transducers can be a phased array.
[0007] In another embodiment of the method, the plurality of plane
waves are not transmitted sequentially.
[0008] In another embodiment of the method, an amount of data
contained within the single A-scan is less than an amount of data
contained within a plurality of A-scans acquired by full matrix
capture (FMC).
[0009] In another embodiment of the method, an amount of data
contained within the single A-scan is less than an amount of data
contained within a plurality of A-scans acquired by plane wave
imaging (PWI).
[0010] In another embodiment of the method, a rate of data
generated during measurement of the single A-scan is less than a
rate of data generated during measurement of a plurality of A-scans
acquired by full matrix capture (FMC).
[0011] In another embodiment of the method, a rate of data
generated during measurement of the single A-scan is less than a
rate of data generated during measurement of a plurality of A-scans
acquired by plane wave imaging (PWI).
[0012] In an embodiment, an ultrasonic testing system is provided
and can include an ultrasonic probe and a controller. The
ultrasonic probe can include a plurality of ultrasonic transducers
arranged in a predetermined array. The plurality of ultrasonic
transducers can also be configured to transmit respective
ultrasonic waves in response to receipt of control signals to form
a plurality of plane wave. The plurality of plane waves are
oriented at different predetermined directions with respect to a
reference axis and the plurality of plane waves are transmitted
substantially simultaneously into the target. The plurality of
ultrasonic transducers can be further configured to receive
ultrasonic echoes resulting from reflection of the plurality of
plane waves from the target. The plurality of ultrasonic
transducers can additionally be configured to measure a single
A-scan characterizing the ultrasonic echoes received at respective
ones of the plurality of ultrasonic transducers. The controller can
include one or more processors and it can be configured to transmit
the control signals to the plurality of ultrasonic transducers. The
controller can be further configured to generate, based upon the
measured A-scans, an image representing the target. The controller
can be additionally configured to output data representing the
generated image to a display device.
[0013] In another embodiment of the system, the plurality of
ultrasonic transducers can be a phased array.
[0014] In another embodiment of the system, the plurality of plane
waves are not transmitted sequentially.
[0015] In another embodiment of the system, an amount of data
contained within the single A-scan is less than an amount of data
contained within a plurality of A-scans acquired by full matrix
capture (FMC).
[0016] In another embodiment of the system, an amount of data
contained within the single A-scan is less than an amount of data
contained within a plurality of A-scans acquired by plane wave
imaging (PWI).
[0017] In another embodiment of the system, a rate of data
generated during measurement of the single A-scan is less than a
rate of data generated during measurement of a plurality of A-scans
acquired by full matrix capture (FMC).
[0018] In another embodiment of the system, a rate of data
generated during measurement of the single A-scan is less than a
rate of data generated during measurement of a plurality of A-scans
acquired by plane wave imaging (PWI).
[0019] In an embodiment, a non-transitory computer program product
which, when executed by at least one data processor forming part of
at least one computer, result in operations including transmitting,
by a plurality of ultrasonic transducers arranged in a
predetermined array, respective ultrasonic waves to form a
plurality of plane waves. The plurality of plane waves can be
oriented at different predetermined directions with respect to a
reference axis and the plurality of plane waves are transmitted
substantially simultaneously into the target. The operations can
also include receiving, by the plurality ultrasonic transducers,
ultrasonic echoes resulting from reflection of the plurality of
plane waves from the target. The operations can further include
measuring, by each ultrasonic transducer of the plurality of
ultrasonic transducers, a single A-scan characterizing the
ultrasonic echoes received at that ultrasonic transducer. The
operations can additionally include generating, by a controller
based upon the measured A-scans, an image representing the target.
The plurality of operations can further include outputting, by the
controller, data representing the generated image to a display
device.
[0020] In another embodiment the plurality of plane waves are not
transmitted sequentially.
[0021] In another embodiment an amount of data contained within the
single A-scan is less than an amount of data contained within a
plurality of A-scans acquired by full matrix capture (FMC).
[0022] In another embodiment an amount of data contained within the
single A-scan is less than an amount of data contained within a
plurality of A-scans acquired by plane wave imaging (PWI).
[0023] In another embodiment a rate of data generated during
measurement of the single A-scan is less than a rate of data
generated during measurement of a plurality of A-scans acquired by
full matrix capture (FMC).
[0024] In another embodiment a rate of data generated during
measurement of the single A-scan is less than a rate of data
generated during measurement of a plurality of A-scans acquired by
plane wave imaging (PWI).
DESCRIPTION OF DRAWINGS
[0025] These and other features will be more readily understood
from the following detailed description taken in conjunction with
the accompanying drawings, in which:
[0026] FIG. 1A is a schematic diagram illustrating one exemplary
embodiment of an operating environment including an ultrasonic
inspection system and a target;
[0027] FIG. 1B is a schematic diagram illustrating the ultrasonic
inspection system of FIG. 1A generating a plurality of ultrasonic
beams simultaneously for evaluation of the target;
[0028] FIG. 2 is a schematic diagram illustrating a controller of
the ultrasonic inspection system of FIGS. 1A-1B.
[0029] FIG. 3A is a schematic diagram illustrating an ultrasonic
testing system employing full matrix capture (FMC) for data
acquisition;
[0030] FIG. 3B is a schematic diagram illustrating an ultrasonic
testing system employing plane wave imaging (PWI) for data
acquisition;
[0031] FIG. 3C is a schematic diagram of an embodiment of the
ultrasonic inspection system of FIGS. 1A-2 employing multi-plane
wave imaging (multi-PWI) for data acquisition; and
[0032] FIG. 4 is a flow diagram illustrating one exemplary
embodiment of a method for ultrasonic testing employing the
ultrasonic inspection system of FIGS. 1A-1B.
[0033] It is noted that the drawings are not necessarily to scale.
The drawings are intended to depict only typical aspects of the
subject matter disclosed herein, and therefore should not be
considered as limiting the scope of the disclosure.
DETAILED DESCRIPTION
[0034] Ultrasonic testing systems have been developed that can
generate multi-dimensional images (e.g., two-dimensional,
three-dimensional) of a target from ultrasonic test data. However,
these systems can require acquisition of a large amount of
ultrasonic data. In order to provide ultrasonic images for display
in real-time, relatively complex electronics can be required to
process the large amount of acquired ultrasonic data quickly.
However, such complex electronics are costly. To address this
issue, systems and methods for ultrasonic testing are provided that
facilitate real-time display of ultrasonic images on less complex
and costly electronics. As discussed in greater detail below,
ultrasonic beams oriented in different directions can be generated
simultaneously by an array of ultrasonic transducers and directed
towards the target. The same ultrasonic transducers can each
acquire a single measurement (e.g., an A-scan of amplitude as a
function of time) for ultrasonic echoes reflected from the target.
The amount of ultrasonic data collected in this manner is
significantly reduced, as compared to existing ultrasonic testing
systems. The reduced amount of ultrasonic data allows image
processing to be performed on relatively low cost electronics
(e.g., mobile processors) at a speed fast enough (e.g.,
milliseconds) to allow real-time display of generated ultrasonic
images.
[0035] FIG. 1A illustrates one exemplary embodiment of an operating
environment 100 including an ultrasonic inspection system 102 and a
target 104. The ultrasonic inspection system 102 can be configured
to measure ultrasonic data characterizing features of the target
104 such as defects (e.g., cracks, porosity, inhomogeneities, etc.)
and to generate images representing such defects. The illustrated
ultrasonic inspection system 102 includes an ultrasonic probe 106,
a controller 110, and a display device 112. The ultrasonic probe
106 can include a plurality of ultrasonic transducers 114, adjacent
to a sensing face 116 of the ultrasonic probe 106, and arranged in
a predetermined layout, referred to as a matrix or array 118. The
controller 110 can include one or more processors. Each of the
ultrasonic transducers 114 can be configured to emit ultrasonic
waves 120 in response to receipt of control signals 110s from the
controller 110. The control signals 110s can be designed such that
the ultrasonic waves 120 interfere with one another to form plane
waves 122, orthogonal to a direction of travel of the plane waves
122. The collection of plane waves 122, traveling at an angle
.theta. with respect to a reference axis A, can be referred to as
an ultrasonic beam B. In this manner, the array 118 of ultrasonic
transducers 114 can function as a phased array. Each of the
ultrasonic transducers 114 can further configured to measure return
measurement signals 114s to the controller 110 characterizing
measured ultrasonic waves 120 reflected from the target 104.
[0036] In use, the sensing face 116 of the ultrasonic probe 106 can
be placed adjacent to the target 104. For example, the sensing face
116 can be placed in direct contact with an outer surface of the
target 104 or a fluid couplant (not shown) can be interposed
between the target 104 and the sensing face 116.
[0037] So positioned, the controller 110 can provide respective
control signals 110s (e.g., excitation pulses) to each of the
ultrasonic transducers 114 to generate ultrasonic waves 120
providing substantially simultaneous transmission of a plurality of
ultrasonic beams B at different angles .theta. (e.g.,
B.sub.1-B.sub.x) into the target, referred to as a shot, as shown
in FIG. 1B.
[0038] In general, each angle of the ultrasonic beam B can require
a delay law for control of ultrasonic waves 120 generated by each
ultrasonic transducer 114. That is, the excitation pulse provided
to each ultrasonic transducer 114 of the phased array 118 can be
delayed by a predetermined amount in order to steer the ultrasonic
beam B to adopt its angle .theta.. These delays can be calculated
based on the pitch (spacing between individual ultrasonic
transducers 114) of the phased array 118 and the velocity of sound
in the target 104. Similarly, the excitation pulses of each
ultrasonic transducer 114 can be calculated to steer the beam in
the different directions with or without focusing. In this manner,
the ultrasound beams B at different angles .theta. and, if
necessary different focusing beams, in one shot. Plane waves, with
a defined aperture (total width of all transducer elements firing
at the same time) and at different angles can be fired in one shot
by pre-calculating the excitation pulses of each ultrasonic
transducer 114.
[0039] Subsequently, each of the ultrasonic transducers 114 can act
as receivers, measuring data characterizing the amplitude and time
of flight of reflected ultrasonic waves (A-scans) for all angles of
the ultrasonic beams B. That is, each ultrasonic transducer 114 can
measure a single A-scan for each shot and output one or more
measurement signals 114s representing its measured A-scan. The
controller 110 can be further configured to analyze the received
measurement signals 114s to generate an image of the target 104.
One or more image signals 112s can be output to the display device
112 for presentation to a user.
[0040] As discussed in greater detail below, ultrasonic imaging of
the target 104 in this manner generates significantly fewer A-scans
as compared to existing ultrasonic imaging techniques. Thus, the
volume of data analyzed by the controller 110 to generate an image
can be significantly less, facilitating rapid processing and
real-time image display without the need for complex, costly
electronics.
[0041] FIG. 2 is a schematic diagram illustrating one exemplary
embodiment of the controller 110 in the form of controller 200. As
illustrated, the controller 200 is in signal communication with the
phased array 118 via control lines 210. While only four
representative control lines 210 are shown in FIG. 2, each
ultrasonic transducer 114 in the phased array 118 can be connected
to the controller 200 by one of the control lines 210, with each of
the control lines 210 operative to transmit electrical signals to
the phased array 118 (e.g., control signals 110s), and for
receiving electrical signals from the phased array 118 (e.g.,
measurement signals 114s).
[0042] The controller 200 can include a transmitter controller 231,
a transmitter settings controller 232, and a cycle controller 241.
The transmitter controller 231 can be configured to send electrical
pulses to the ultrasonic transducers 114 in the phased array 118
over the control lines 210. Upon receipt of the electrical pulses,
the ultrasonic transducers 114 can convert the electrical pulses
into the ultrasonic waves 120. The transmitter settings controller
232 can be configured to provide the transmit delays for each of
the ultrasonic transducers 114 to the transmitter controller 231 to
coordinate a timing relationship for subsets of the ultrasonic
transducers 114 to transmit an ultrasonic beams B at a
predetermined angle .theta.. The cycle controller 241 can be
connected to the transmitter settings controller 232 and it can be
configured to coordinate and correlate the transmission of the
ultrasonic waves 120 at different angles .theta..
[0043] In addition to being connected to the transmitter controller
231, each ultrasonic transducer 114 of the phased array 118 can
also be connected to an amplifier 221, a filter 222, and an analog
to digital (A/D) converter 223 for receiving and digitizing
reflected ultrasonic waves from the target 104. The reflected
ultrasonic waves can be measured from the ultrasonic waves 120
transmitted by the same phased array 118.
[0044] The controller 200 can also include one or more receivers
233, receiver settings device 235, evaluation units 242, and
storage devices 234. As an example, each of the receivers 233 can
be connected to one or more of the A/D converters 223 and
configured to receive digitized data representing the reflected
ultrasonic waves regarding the target 104. The exact combination of
data received by a given one of the receivers 233 can depend upon
the processing requirements for any particular testing scheme
employed by the ultrasonic inspection system 102. Outputs from each
of the receivers 233 can be received for immediate processing at an
evaluation units 242. In further embodiments, one of the storage
devices 234 can be connected to each of the receivers 233 and
configured to receive outputs from each of the receivers 233 for
storage. The receivers 233 can also be configured to receive inputs
from the receiver settings device 235 that include delay data
determined in combination with the coordinated transmit delays in
the transmitter settings controller 232, described above, under
control of the cycle controller 241 for managing appropriate delay
correlations between timed pulses for generating the ultrasonic
waves 120 and received reflected ultrasonic echoes.
[0045] Embodiments of the controller 200 can also include one or
more evaluation units 242 and one or more processors 250. The
evaluation units 242 can receive outputs from the receivers 233 and
can be further in communication with the cycle controller 241. The
evaluation units 242 can be configured to analyze the ultrasonic
digitized data and generate A-scan information as an output to
processors 250. The processors 250 can be further configured to
generate multi-dimensional images from the received A-scan
information and transmit the generated multidimensional images as
the image signals 112s for display by the display device 112.
Examples of imaging generation techniques employed by the
processors 250 can include time domain or frequency domain imaging
techniques. In one aspect, time domain imaging techniques can
include synthetic aperture focusing (SAFT) and total focusing
method (TFM). In another aspect, frequency domain imaging
techniques can include Fourier transformed SAFT (FTSAFT), also
referred to as f-k migration.
[0046] By employing multiple ultrasonic beams B fired
simultaneously in a single shot, a significant reduction in measure
A-scan data can be achieved. This data reduction can be understood
with reference to FIGS. 3A-3C, illustrating ultrasonic data
acquisition according to the full matrix capture (FMC) technique
and the plane wave imaging (PWI) technique as compared to
embodiments of the multi-plane wave imaging technique discussed
herein.
[0047] The FMC technique is illustrated in FIG. 3A. As shown,
single transducers of a phased array are fired consecutively, while
each of the single transducers acts as a receiver of the reflected
ultrasonic echoes. Assuming a phased array containing E transducer
elements, each transducer measures E A-scans. This gives a total of
E.times.E A-scans measured when each transducer element is fired a
single time. Further assuming that each transducer is fired in a
set N times, the total number of A-scans measured using the FMC
technique is E.times.E.times.N.
[0048] The PWI technique is illustrated in FIG. 3B. As shown,
transducers of a phased array fire plane waves using a defined
aperture of the phased array and single transducers of the phase
array probe act as receivers of the reflected ultrasonic echoes.
Transmission and reception are performed sequentially. Assuming a
phased array containing E transducer elements, and P plane waves at
different angles, each transducer measures P A-scans. This gives a
total of E.times.P A-scans measured when each plane wave is fired
once. Further assuming that each plane wave is fired in a set N
times, the total number of A-scans measured using the FMC technique
is E.times.P.times.N.
[0049] An embodiment of multi-plane wave technique discussed herein
is illustrated in FIG. 3C. As shown, the ultrasonic transducers 114
of the phased array 118 fire a single plane wave using a defined
aperture of the phased array 118 and each ultrasonic transducer 114
of the phased array 118 acts as a receiver of the reflected
ultrasonic echoes. Assuming a phased array containing E transducer
elements, and all plane waves at different angles fired
simultaneously P, each transducer measures a single A-scans. This
gives a total of E.times.1 A-scans measured when each plane wave is
fired once. Further assuming that each plane wave is fired in a set
N times, the total number of A-scans measured using the FMC
technique is E.times.1.times.N.
[0050] In general, regardless of the values assumed for E, P, and
N, multi-PWI employs less A-scans than either FMC or PWI. For
example, multi-PWI employs 1/E less A-scans compared to FMC and 1/P
less A-scans compared to PWI. Assuming 64 transducer elements are
present (E=64), 20 plane wave angles (P=20), multi-PWI employs 20
times fewer A-scans than PWI and 64 times fewer A-scans than
FMC.
[0051] To better appreciate the data savings achieved by reducing
the amount of A-scans, it is helpful to assume real-world values
for the parameters discussed above, shown in Table 1 and discussed
below.
TABLE-US-00001 TABLE 1 Comparison of data usage Number of Data
Generated Data Generation A-scans Per Set (MB) Rate (MB/sec) FMC 64
.times. 64 .times. 1024 8 240 (4,194,304) PWI 64 .times. 20 .times.
1024 2.5 75 (1,310,720) Multi-PWI 64 .times. 1 .times. 1024 0.125
3.75 65,536
[0052] For example, assume a set of 1024 A-scans are performed
(N=1024). FMC results in 4,194,304 A-scans per set, PWI results in
1,310,720 A-scans per set, and multi-PWI results in 65,536 A-scans
per set. Further assuming that each A-scan uses 2 bytes (2B) of
data storage, FMC uses 8 MB for each set of A-scans performed, PWI
uses 2.5 MB for each set of A-scans performed, and multi-PWI uses
0.125 MB for each set of A-scans performed. Further assuming a
sampling rate of 30 Hz, where each set of A-scans is performed 30
times per second, FMC generates data at a rate of 240 MB/sec, PWI
generates data at a rate of 240 MB/sec, and multi-PWI generates
data at a rate of 3.75 MB/sec.
[0053] FIG. 4 is a flow diagram illustrating one exemplary
embodiment of a method 400 for ultrasonic testing including
operations 402-414. The method is discussed below with reference to
the ultrasonic inspection system 102 of FIGS. 1A-2. Alternative
embodiments of the method can include greater or fewer operations
and the operations can be performed in an order different than that
illustrated in FIG. 4.
[0054] In operation 402, the ultrasonic probe 106 is positioned
adjacent to the target 104. As an example, the sensing face 116 of
the ultrasonic probe 106 can be positioned directly in contact with
the target 104 or a layer of a couplant (e.g., a fluid couplant)
can be interposed between the sensing face 116 and the target 104.
The ultrasonic probe 106 can include the plurality of ultrasonic
transducers 114.
[0055] In operation 404, the plurality of ultrasonic transducers
114 can transmit respective ultrasonic waves 120 into the target
104. The transmitted ultrasonic waves 120 can be configured to
interfere with one another to form the plurality of plane waves
122. Each of the plane waves 122 can be oriented at different
predetermined directions (e.g., different angles .theta.) with
respect to the reference axis A. As an example, the controller 110
can provide control signals 110s operative to cause the plurality
of transducers to transmit the plurality of ultrasonic waves
120.
[0056] In operation 406, the plurality of ultrasonic transducers
114 can receive ultrasonic echoes resulting from reflection of the
plurality of plane waves 122 from the target 104. In operation 410,
each ultrasonic transducer of the plurality of ultrasonic
transducers can measure a single A-scan (e.g., amplitude as a
function of time or time of flight). The single A-scan received at
a given ultrasonic transducer 114 can characterize the ultrasonic
echoes received at that ultrasonic transducer.
[0057] In operation 412, the controller 110 can receive one or more
measurement signals 114s from each ultrasonic transducer 114
representing the A-scan measured by that ultrasonic transducer 114.
Based upon these measured A-scans, the controller 110 can generate
an image representing the target 104. As an example, the image can
be a multi-dimensional image (e.g., two-dimensional,
three-dimensional, etc.) including representation of one or more
defects and/or geometric features of the target 104.
[0058] In operation 414, data representing the generated image
(e.g., image signals 112s) to the display device 112. In certain
embodiments, the generated image can be output and displayed
substantially concurrently with transmission of the plurality of
ultrasonic waves 120 into the target 104. In this manner, images of
the target 104 can be displayed in real-time with performance of
ultrasonic testing.
[0059] Exemplary technical effects of the methods, systems, and
devices described herein include, by way of non-limiting example
reduction of data acquired when performing ultrasonic testing of
target materials. This data reduction enables processing of
acquired ultrasonic data in real-time without use of complex and
costly electronic components. Significant cost savings can be
achieved as a result.
[0060] Certain exemplary embodiments have been described to provide
an overall understanding of the principles of the structure,
function, manufacture, and use of the systems, devices, and methods
disclosed herein. One or more examples of these embodiments have
been illustrated in the accompanying drawings. Those skilled in the
art will understand that the systems, devices, and methods
specifically described herein and illustrated in the accompanying
drawings are non-limiting exemplary embodiments and that the scope
of the present invention is defined solely by the claims. The
features illustrated or described in connection with one exemplary
embodiment may be combined with the features of other embodiments.
Such modifications and variations are intended to be included
within the scope of the present invention. Further, in the present
disclosure, like-named components of the embodiments generally have
similar features, and thus within a particular embodiment each
feature of each like-named component is not necessarily fully
elaborated upon.
[0061] The subject matter described herein can be implemented in
analog electronic circuitry, digital electronic circuitry, and/or
in computer software, firmware, or hardware, including the
structural means disclosed in this specification and structural
equivalents thereof, or in combinations of them. The subject matter
described herein can be implemented as one or more computer program
products, such as one or more computer programs tangibly embodied
in an information carrier (e.g., in a machine-readable storage
device), or embodied in a propagated signal, for execution by, or
to control the operation of, data processing apparatus (e.g., a
programmable processor, a computer, or multiple computers). A
computer program (also known as a program, software, software
application, or code) can be written in any form of programming
language, including compiled or interpreted languages, and it can
be deployed in any form, including as a stand-alone program or as a
module, component, subroutine, or other unit suitable for use in a
computing environment. A computer program does not necessarily
correspond to a file. A program can be stored in a portion of a
file that holds other programs or data, in a single file dedicated
to the program in question, or in multiple coordinated files (e.g.,
files that store one or more modules, sub-programs, or portions of
code). A computer program can be deployed to be executed on one
computer or on multiple computers at one site or distributed across
multiple sites and interconnected by a communication network.
[0062] The processes and logic flows described in this
specification, including the method steps of the subject matter
described herein, can be performed by one or more programmable
processors executing one or more computer programs to perform
functions of the subject matter described herein by operating on
input data and generating output. The processes and logic flows can
also be performed by, and apparatus of the subject matter described
herein can be implemented as, special purpose logic circuitry,
e.g., an FPGA (field programmable gate array) or an ASIC
(application-specific integrated circuit).
[0063] Processors suitable for the execution of a computer program
include, by way of example, both general and special purpose
microprocessors, and any one or more processor of any kind of
digital computer. Generally, a processor will receive instructions
and data from a read-only memory or a random access memory or both.
The essential elements of a computer are a processor for executing
instructions and one or more memory devices for storing
instructions and data. Generally, a computer will also include, or
be operatively coupled to receive data from or transfer data to, or
both, one or more mass storage devices for storing data, e.g.,
magnetic, magneto-optical disks, or optical disks. Information
carriers suitable for embodying computer program instructions and
data include all forms of non-volatile memory, including by way of
example semiconductor memory devices, (e.g., EPROM, EEPROM, and
flash memory devices); magnetic disks, (e.g., internal hard disks
or removable disks); magneto-optical disks; and optical disks
(e.g., CD and DVD disks). The processor and the memory can be
supplemented by, or incorporated in, special purpose logic
circuitry.
[0064] To provide for interaction with a user, the subject matter
described herein can be implemented on a computer having a display
device, e.g., a CRT (cathode ray tube) or LCD (liquid crystal
display) monitor, for displaying information to the user and a
keyboard and a pointing device, (e.g., a mouse or a trackball), by
which the user can provide input to the computer. Other kinds of
devices can be used to provide for interaction with a user as well.
For example, feedback provided to the user can be any form of
sensory feedback, (e.g., visual feedback, auditory feedback, or
tactile feedback), and input from the user can be received in any
form, including acoustic, speech, or tactile input.
[0065] The techniques described herein can be implemented using one
or more modules. As used herein, the term "module" refers to
computing software, firmware, hardware, and/or various combinations
thereof. At a minimum, however, modules are not to be interpreted
as software that is not implemented on hardware, firmware, or
recorded on a non-transitory processor readable recordable storage
medium (i.e., modules are not software per se). Indeed "module" is
to be interpreted to always include at least some physical,
non-transitory hardware such as a part of a processor or computer.
Two different modules can share the same physical hardware (e.g.,
two different modules can use the same processor and network
interface). The modules described herein can be combined,
integrated, separated, and/or duplicated to support various
applications. Also, a function described herein as being performed
at a particular module can be performed at one or more other
modules and/or by one or more other devices instead of or in
addition to the function performed at the particular module.
Further, the modules can be implemented across multiple devices
and/or other components local or remote to one another.
Additionally, the modules can be moved from one device and added to
another device, and/or can be included in both devices.
[0066] The subject matter described herein can be implemented in a
computing system that includes a back-end component (e.g., a data
server), a middleware component (e.g., an application server), or a
front-end component (e.g., a client computer having a graphical
user interface or a web browser through which a user can interact
with an implementation of the subject matter described herein), or
any combination of such back-end, middleware, and front-end
components. The components of the system can be interconnected by
any form or medium of digital data communication, e.g., a
communication network. Examples of communication networks include a
local area network ("LAN") and a wide area network ("WAN"), e.g.,
the Internet.
[0067] Approximating language, as used herein throughout the
specification and claims, may be applied to modify any quantitative
representation that could permissibly vary without resulting in a
change in the basic function to which it is related. Accordingly, a
value modified by a term or terms, such as "about,"
"approximately," and "substantially," are not to be limited to the
precise value specified. In at least some instances, the
approximating language may correspond to the precision of an
instrument for measuring the value. Here and throughout the
specification and claims, range limitations may be combined and/or
interchanged, such ranges are identified and include all the
sub-ranges contained therein unless context or language indicates
otherwise.
[0068] One skilled in the art will appreciate further features and
advantages of the invention based on the above-described
embodiments. Accordingly, the present application is not to be
limited by what has been particularly shown and described, except
as indicated by the appended claims. All publications and
references cited herein are expressly incorporated by reference in
their entirety.
* * * * *